The Process Operator - Heart of Production

Abstract

When installing process control computer systems, too much emphasis is often placed on sophisticated control theory and on that mysterious black box rather than on the exceptions and abnormal situations, and on the necessary communications with those people responsible for production. Effective operator communication is the key to successful implementation of process control computer systems. This paper reviews operator communication requirements from a practical viewpoint based on experience with process computer systems, and discusses basic principles that should be included in the design of computer/operator communications. Typical computer display and data input functions found in an industrial process environment are discussed. Devices for accomplishing those functions are reviewed and critiqued from the viewpoint of adaptability to the industrial environment and in meeting the requirements of the operator. Hardware interface, computer system design, and programming considerations are presented. Mead's recent computer installation at its Escanaba, Michigan, paper mill incorporates many of the points made in the paper, resulting in a system of man/machine communications for process control, reporting functions, and data entry that has been successful since its installation two years ago. An effective operator training program prior to actual startup of the production facilities assured that intimidation by the computer and poor computer communications would not be operating problems.